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PLC Troubleshooting & Maintenance

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Manual Work
Brain Senses Motion Energy

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Human Lags:

Human

Cannot Work 24 Hours Cannot work with 100% Accuracy & precision Efficiency decreases as energy decreases

Controllers

Automatic Work
Actuators

Sensors

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Advantages:
Accuracy No idle Time More Production

Machine

Energy

Lags:

Regular Troubleshooting & Maintenance

What is Controllers?
Controller is a part of Automatic Control System, which process the signal from sensors & send it to the actuators

Sensors

Controller

Actuator

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A closed Loop Control System

This is a PLC

Input Terminals

Output Terminals

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Programming Cable

D/A Card A/D Card

RS 485

This is a PLC

Power 24 VDC

Battery Input Terminals

Output Terminals

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Programming Cable

This is a PLC

Output Terminals Input Terminals

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Programming Cable

Power 24 VDC

Understanding PLC

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Understanding PLC

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How to Select a PLC?

Step 1:
Selecting the Inputs - Number of Inputs - Input Types NPN or PNP - Nature of Inputs Digital or Analog - Voltage rating of the Inputs Step 2: Step 3: Length of Program Big or Small Nature of Program Ladder Logic, SFC, Instruction List, FDB

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Selecting the Outputs - Number of Outputs - Nature of Outputs Digital or Analog - Voltage rating of the Inputs

Programming Languages
Ladder Logic SFC

Instruction List

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FDB

PLC Ladder Logic

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Common Industrial Hardware Representing the Binary Concept

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Basics of Machine Language

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Basics of Machine Language

Bits Nibble - Byte Word

Unlike

English, computers have only two characters available 1 or 0. Each 1 or 0 is called a binary digit or bit. Binary is base or radix 2

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PLC

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Inputs & Outputs

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Digital Inputs & Outputs

Typical Digital Input/ Output Signals
12 VDC 24 VDC 120 VAC 240 VAC

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Analog Inputs

PLC INPUTS & OUTPUTS

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Typical analog signals come from temperature, pressure, position, and motor speed. Analog input modules convert analog signals to digital words. Analog input signals are current or voltage.

Typical Analog input signals

0 to 10 volts DC -10 to +10 volts DC 0 to 5 or 1 to 5 volts DC 4 to 20 milliamps 0 to 20 milliamps -20 to +20 milliamps

PLC INPUTS & OUTPUTS

Connections from Field Devices

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Image courtesy of Allen-Bradley, a Rockwell Automation business

PLC INPUTS & OUTPUTS

Differential Analog Input Connections

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Image courtesy of Allen-Bradley, a Rockwell Automation business

Analog Outputs

PLC INPUTS & OUTPUTS

Typical analog signals are required by Servo Valves, VFDs, Servo Motors, Meters Analog Output modules convert Digital bits to analog signal. Analog Output signals are current or voltage.

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Typical Analog Output signals

0 to 10 volts DC -10 to +10 volts DC 0 to 5 or 1 to 5 volts DC 4 to 20 milliamps 0 to 20 milliamps -20 to +20 milliamps

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PLC Enclosure & System Components

NEMA 12
National Electric Manufacturer Association, USA

PLC Enclosure

Prevents:

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Dust Water Oil Mostly used for Indoor applications of automation. Some examples are Packaging Material handling Non-corrosive process control. NEMA enclosures are available in sizes from small wall mounts to multi-door freestanding models.

Enclosure Layout

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Placement of PLC Components

To allow maximum cooling

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All Controller components should be mounted in a vertical (upright) position.

Duck & Wire Layout

Keep AC signals separate from DC Signals DC Signals I/O lines, such as TTL and analog AC Signals Incoming Line Wires

Minimizes the possibility of electrical noise pickup.

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Power Requirement & Safety Circuitry

POWER REQUIREMENTS
Typical Power Requirement 220 VAC

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SAFETY CIRCUITRY
Door Switch

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Pull Rope Switch Emergency Switch

Automation Studio

Master or Safety Control Relays

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Automation Studio

PLC FAULT CONTACT PROTECTION

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Automation Studio

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PLC Maintenance
HEAT, DUST & NOISE
REGULATION

PLC MAINTENANCE HEAT & DUST REGULATION

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Temperature Withstand Range

0 ~ 60C

PLC MAINTENANCE

NOISE REGULATION

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Shielded Cables for better communication

PLC MAINTENANCE

NOISE GENERATING DEVICES

MOTOR STARTERS

SOLENOIDS

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RELAYS AND CONTACTORS

VARIABLE FREQUENCY DRIVES

PLC TROUBLESHOOTING 2

NOISE FROM GROUNDING

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PLC

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I/O Installation, Wiring & Precautions

I/O INSTALLATION, WIRING, AND PRECAUTIONS

I/O MODULE INSTALLATION

Placement and installation of the I/O modules is simply a matter of inserting the correct modules in their proper locations. This procedure involves verifying the type of module (220 VAC/ 24 VDC output, 220 VDC/ 24 VDC input, etc.) and the slot address as defined by the I/O address assignment document. Each terminal in the module is then wired to the field devices that have been assigned to that termination address. The user should remove power to the modules (or rack) before installing and wiring any module.11

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I/O INSTALLATION, WIRING, AND PRECAUTIONS

WIRE SIZE CONSIDERATION

WIRING

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I/O INSTALLATION, WIRING, AND PRECAUTIONS

WIRE SIZE CONSIDERATION

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WIRE LABELLING

I/O INSTALLATION, WIRING, AND PRECAUTIONS

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I/O INSTALLATION, WIRING, AND PRECAUTIONS

WIRE BUNDLING

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PLC

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START-UP & CHECKING PROCEDURES

PLC START-UP AND CHECKING PROCEDURES

Model numbers Placement

Power Supply Inspection

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Verify Field Wiring & I/O comm. cables

STATIC INPUT/ OUTPUT WIRING CHECK

Input Terminals

Output Terminals

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PLC

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PREVENTIVE MAINTENANCE

PLC PREVENTIVE MAINTENANCE

Regular Filter Cleaning

Regular Dusting Dust restricts heat dissipation Avoid Conductive Dust I/O Module Check for any Loose connections

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Avoid Noise generating Equipment close to PLC

Avoid documentation to create HOT SPOT

Install vibration Detector in area of high vibration

PLC PREVENTIVE MAINTENANCE

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PLC

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TROBLESHOOTING AREAS

POWER LED IS TURNED OFF

Is power supply operating?

NO

Is Power Indicator Lit?

Supply the power

YES NO

NO

Does the power LED turned on?

YES

Is the voltage within the rated power?

See the power supply within 180 ~ 240 VAC

YES
Is the fuse blown?

NO

Does the power LED turned on?

YES

YES

Replace the Fuse

NO
Is the power Supply cable Connected?

NO

Does the power LED turned on?

YES

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NO YES NO
Over current Device activated?

Connect the power supply properly

YES

Does the power LED turned on?

YES

Eliminate excess current & switch power ON/OFF

NO

Write the steps & Contact customer care

NO

Does the power LED turned on?

YES

COMPLETE

RUN INDICATOR NOT LIT

RUN Indicator not Lit

YES
Is PC mode Displayed on Programming Device?

NO

Is the ERR/ALM Indicator Lit?

NO

YES
Determine the cause of the error with the Programming device

Is PC mode displayed On Programming device?

NO

Turn the power supply OFF & then ON again

YES

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Is a fatal error Displayed?

YES

Identify the error, eliminate its cause, & clear the error.

NO

Switch to RUN or MONITOR mode

Is the RUN Indicator lit?

NO

YES

END

Replace the CPU Unit

FATAL ERROR CHECK

Program cannot be written

PROGRAM CANNOT BE WRITTEN TO PLC

Is the mode setting Switch set to the remote stop?

NO

Switch to the remote STOP mode & execute the program mode

YES

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NO

NO

Is ERR LED Blinking?

After reading error code by using peripheral device, correct the content

COMPLETE

Environment Condition Check

ENVIRONMENT CONDITION CHECK

Is the ambient temperature below 55 degree?

NO

Consider using a FAN or COLLER

YES
Is the ambient temperature above 0 degree?

NO
Consider using a HEATER

YES
Is the ambient humidity between 10% ~ 85%

NO

Consider using an air conditioner

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Is noise being controlled?

YES

NO

Install surge protectors or other noise reducing equipment at noise sources

YES

NO
Consider constructing an instrument panel or cabinet

Is the installation environment ok?

YES

END

ERR/ALM Indicator flashing

Determine the cause of the error with a programming device

ERR/ALM INDICATOR FLASHING

IS a non fatal error Indicated?

YES

Identify the error, eliminates its cause & clear the error

NO

Is the ERR/ALM Indicator flashing?

FLASHING

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Replace the CPU Unit

NO

END

NON- FATAL ERROR CHECK

MALFUNCTIONING OF SOL 1

0002

0003
01003 SOL 1

I/O CHECK

01003

Is the IR 01003 output Indicator operating?

NO

YES
Check the voltage at IR 01003 terminals Wire correctly Correct the short circuit or limit the connected load to the specified range Monitor the ON/OFF status of IR 01003 with the Programming Device

NO NO

Operation ok?
YES

Is the Output wiring correct?

YES
Is the external power supply Shorted or overload?

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YES

YES

NO

Disconnect the external wires & check the conductivity of each wire

Operation ok?

NO

Check output device SOL 1.

Replace the CPU Unit, Expansion Unit, or Expansion I/O Unit with the problem

Next slide

YES

Operation ok?

NO

0002

0003
01003 SOL 1

I/O CHECK

01003

From previous slide

Are the IR 0002 & IR 0003 Input indicators operating Normally?

NO

YES
Check the voltage at the IR 0002 & IR 0003 terminals

Check the voltage at the IR 0002 & IR 0003 terminals

Operation ok?
NO YES NO

YES

Operation ok?
YES

Is the wiring correct?

YES

Are the terminals screws loose? NO

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NO
Operation ok?

Check operation by using a dummy input signal to turn the input ON & OFF

NO
Wire Correctly Tighten the terminal screws

Replace the CPU Unit, Expansion Unit, or Expansion I/O Unit with the problem

Check input devices LS1 & LS2

Return to Start

Replace the CPU Unit, Expansion Unit, or Expansion I/O Unit with the problem

Thanks

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